Method for placing magnet segments for an axial flux machine

Abstract

According to one disclosed method, a magnet segment may be slid linearly along a first surface and onto a second surface of a back iron of a rotor, wherein the first surface is disposed at or above a rim that extends upwardly from the second surface at an outer edge of the back iron to enable the magnet segment to slide over the rim before the magnet segment is slid onto the second surface. According to another disclosed method, a first end of a magnet segment may be pressed against an elastic member located at an inner portion of a back iron for a rotor so that force exerted by the elastic member pushes a second end of the magnet segment against a rim located at an outer portion of the back iron.

What is claimed is: 
     
       1. A method, comprising:
 affixing a jig including an elastic member to a back iron for a rotor so that the elastic member is positioned at an inner portion of the back iron; 
 after affixing the jig to the back iron, moving a magnet segment relative to the back iron so that the magnet segment comes into contact with the elastic member; and 
 pressing a first end of the magnet segment against the elastic member so that force exerted by the elastic member pushes a second end of the magnet segment against a rim located at an outer portion of the back iron. 
 
     
     
       2. The method of  claim 1 , further comprising:
 prior to pressing the first end of the magnet segment against the elastic member, applying an adhesive to at least one of a bottom of the magnet segment or a surface of the back iron to which the magnet segment is to be attached. 
 
     
     
       3. The method of  claim 1 , wherein the elastic member comprises an O-ring. 
     
     
       4. The method of  claim 1 , wherein:
 moving the magnet segment relative to the back iron comprises sliding the magnet segment linearly along a first surface and onto a second surface of the back iron to cause the magnet segment to contact the elastic member; 
 the rim extends upwardly from the second surface at the outer portion; and 
 the first surface is disposed at or above the rim to enable the magnet segment to slide over the rim before the magnet segment is slid onto the second surface. 
 
     
     
       5. The method of  claim 4 , further comprising:
 using a pushing member of a magnet placement device to push the magnet segment along the first surface and onto the second surface. 
 
     
     
       6. The method of  claim 5 , further comprising:
 prior to using the pushing member to push the magnet segment along the first surface, using the pushing member to push the magnet segment from a bottom of a stack of magnet segments. 
 
     
     
       7. The method of  claim 6 , further comprising:
 using the pushing member to push a spacer disposed between the magnet segment and another magnet segment in the stack of magnet segments, together with the magnet segment, toward the back iron; and 
 prior to using the pushing member to push the magnet segment onto the second surface, using a component of the magnet placement device to separate the spacer from the magnet segment. 
 
     
     
       8. The method of  claim 5 , further comprising:
 prior to using the pushing member to push the magnet segment onto the second surface, using a magnetization jig of the magnet placement device to magnetize the magnet segment. 
 
     
     
       9. The method of  claim 5 , wherein the magnet placement device includes a soft magnetic member oriented along a linear path, and the method further comprises:
 using the pushing member to push the magnet segment along at least a portion of the first surface such that a magnetic attraction between the magnet segment and the soft magnetic member causes a longest axis of the magnet segment to align with the linear path. 
 
     
     
       10. The method of  claim 4 , wherein affixing the jig to the back iron comprises:
 affixing the jig to the second surface so that the jig defines at least a first pocket to receive the magnet segment on the second surface. 
 
     
     
       11. The method of  claim 10 , wherein:
 the elastic member is disposed on the jig so that, when the jig is affixed to the second surface, a portion of the elastic member is located in the first pocket at the inner portion of the back iron. 
 
     
     
       12. The method of  claim 11 , wherein the elastic member comprises an O-ring. 
     
     
       13. The method of  claim 10 , further comprising:
 prior to sliding the magnet segment onto the second surface, applying an adhesive to at least one of a bottom of the magnet segment or a region of the second surface within the first pocket. 
 
     
     
       14. The method of  claim 13 , further comprising:
 after sliding the magnet segment onto the second surface, removing the jig from the second surface. 
 
     
     
       15. The method of  claim 14 , further comprising:
 waiting for the adhesive to at least partially cure prior to removing the jig from the second surface. 
 
     
     
       16. The method of  claim 10 , further comprising:
 using a pushing member of a magnet placement device to push the magnet segment along the first surface and onto the second surface within the first pocket. 
 
     
     
       17. The method of  claim 16 , further comprising:
 prior to using the pushing member to push the magnet segment along the first surface, using the pushing member to push the magnet segment from a bottom of a stack of magnet segments. 
 
     
     
       18. The method of  claim 17 , further comprising:
 using the pushing member to push a spacer disposed between the magnet segment and another magnet segment in the stack of magnet segments, together with the magnet segment, toward the first pocket; and 
 prior to using the pushing member to push the magnet segment onto the second surface, using a component of the magnet placement device to separate the spacer from the magnet segment. 
 
     
     
       19. The method of  claim 16 , further comprising:
 prior to using the pushing member to push the magnet segment onto the second surface, using a magnetization jig of the magnet placement device to magnetize the magnet segment. 
 
     
     
       20. The method of  claim 16 , wherein the magnet placement device includes a soft magnetic member oriented along a linear path, and the method further comprises:
 using the pushing member to push the magnet segment along at least a portion of the first surface such that a magnetic attraction between the magnet segment and the soft magnetic member causes a longest axis of the magnet segment to align with the linear path. 
 
     
     
       21. The method of  claim 16 , further comprising:
 prior sliding the magnet segment along the first surface and onto the second surface, attaching the back iron to a rotary table; and 
 after affixing the jig to the second surface and attaching the back iron to the rotary table, operating the rotary table to rotate the first pocket to be aligned with an end of the magnet placement device. 
 
     
     
       22. The method of  claim 10 , wherein the rim is a component of the jig. 
     
     
       23. The method of  claim 1 , wherein:
 the rim is configured and arranged to restrict outward radial movement of the magnet segment when the rotor rotates about an axis of rotation. 
 
     
     
       24. The method of  claim 1 , wherein the rim is integral with the back iron.